Wall and ceiling construction



Jan. 1, 1935. G. R. WALPER 1,986,309

l WALL AND CEILING CONSTRUCTION 4 Sheets-Sheet 2 Original Filed Dec.' 2,1929 INVENTOR Gard??? .irai/wref ATTORNEYAZl Jan. l, 1935. G. R. WALPER1,986,309

WALL AND CEILING CONSTRUCTION Original Filed Dec. 2, 1929 4Sheets-Sheatl 3 ATTOFiNEYSl Jan. 1, 1935. G, R WALPER 1,986,309

WALL AND CEILING CONSTRUCTION Original Filed Dec. 2, 19294,Shee'cs-Sheerl 4 INVENTOR Patented Jan. 1, 1935 UNITED STATES PATENTOFFICE.

WALL AND CEILING CONSTRUCTION Gordon a. wanner, Huntington woods, Mich.,as. signor to Curry Ora Walper, Royal Oak, Mich.

Application December 2, 1929, Serial No. 411,189 Renewed June 4, 1934 9Claims. (Cl. 'l2-115) erally methods and means of this character.

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In wall and ceiling constructions of the character to which thisinvention particularly pertains it is customary to provide channelmembers adapted to receive the parallel edges of the plaster boards orthe like,to reinforce and support the same with respect to the studdingor other frame members. In wall or ceiling structures, wherein thechannel members are secured to wooden frame members, attachment ispreferably made by means of driven headed members, and instructureswherein steel channel-shaped frame members or studding isemployed, the channel meme bers are customarily secured in place bymetallic attaching clips.

The present invention contemplates improvements in the elements andmembers from which such wall and ceiling structures are constructed, andhas as its object generally to simplify, cheapen and otherwisefacilitate the manufacture of these elements and members; to provide astructure which may be quickly and easily assembled; and one which willbe strong, durable and otherwise commercially satisfactory.

To this end one of the important objects of this invention is to providean improved construction of double channel-shaped members which may bequickly and economically produced in large quantities, either from asingle strip of metal bent to produce the desired construction or fromtwo strips of metal which are iirst suitably shaped and thensubsequently united to produce the desired double channel-shaped member.

Still another object of the invention is to provide, in connection withany of the forms of channel members herein illustrated. meansconstituting and providing a plaster gauge whereby a minimum thicknessfor the plaster coat, which is subsequently applied to the wall orceiling structure, is established.

The invention further contemplates and has as its objects improvementsin the means for attaching the double channel members to both wooden andmetallic studding or frame members;

to the means for insuring an adequate union or bond between the plastercoat and the double channel member; and to the means for reinforcing andotherwise strengthening the attaching elements employed in connectionwith the metallic frame members.

In addition, the invention contemplates a construction wherein a solidsection of plaster is made possible at the joints supported by thedouble channel members so that expansion and,

contraction at these points is made uniform and the possibility ofsurface cracking eliminated. Another important object of the inventionis to provide a wall and ceiling construction of the described characterwherein, when wooden frame members are employed, the plaster boardsupporting means cooperate therewith to'rigidly tie together the spacedframe members, whereby a strong, rigid and commercially practicable wallor ceiling is produced.

The invention further contemplates the use of pre-marked plaster boardsor the like, whereupon the cutting of the boards to size to com-` pleteirregular-shaped portions of the wall and ceiling is facilitated.

The several objects, advantages and novel details of this constructionwill be made more apparent as this description proceeds, especially whenconsidering the accompanying drawings wherein,

Figure 1 is a vertical section through a wall and ceiling construction,showing in general the application of the present invention;

Figure 2 is an enlarged sectional view taken substantially on 'the planeindicated by line 2 2 in Figure 1;

Figures 3, 4 and 5 are views showing the manner in which one of thesections of one of the forms of channel member is developed;

Figure 6 is a view showing semi-diagrammatically the manner in which theplaster gauge projections can be formed in the channel part illustratedin Figures 3, 4 and 5;

Figure 7 is a fragmentary perspective view of this form of channelmember;

Figure 8 is aA fragmentary sectional view showing semi-diagrammaticallyone means by which the sections of channel member, illustrated in Figure7, may be united;

Figure 9 is a central vertical sectional view through a portion of achannel member united in accordance with the means illustrated in Figure8; Figure 10 is an edge view of the blank from which another form ofdouble channel member may be developed;

Figure 11 is a sectional view through the form of channel memberdeveloped from the single strip of metal illustrated in Figure 10;

Figure 12 is a view somewhat similar to Figure 11 of a slightly modified'form of channel construction developed from a single strip of etal;

Figure 13 is a fragmentary perspective view ofv l age means:

Figures 21 and 22 are respectively transverse sectional and elevationalviews of a double channel member formed of two separate channels unitedin the manner illustrated senil-diagrammaticallyrin Figure 8;

Figure 23 is a fragmentary sectional view through a wall constructionillustrating a modied means for securing the channel member to thstudding; s

Figure 24 is a similar view but modified to the extent that the channelsecuring means constitutes the plaster gauge;

Figure 25 is a fragmentary perspective view showing the double channelmembers attached to a steel frame member;

Figure 26 is a perspective view of one of the attaching clips employed;

Figure 27 is a view illustrating more clearly the manner in which theattaching clip illustrated in Figures 25 and 26 is connected to theframe member;

Figure 28 is a fragmentary perspective view 4'showing a modified form ofan vattaching clip associated with the frame member;

Figure 29 is a similar view showing still another modified form ofattaching clip;

Figure 30 is a similar view showing another 'modified form of attachingclip;

Figure 31 is a sectional view through a clip taken substantially on aplane indicated by the line 31-31 in Figure 29;

Figure 32 isa fragmentary vertical sectional view of a ceilingconstruction showing in general the application of the present inventionwhen metal frame members are employed;

Figures 33 and 34 are perspective views of modied forms of attachingclips;

Figure 35 is a view of still another modified form of attaching clip;

Figure 36 is a sectional view through a different l form of frame membershowing the clip and channel member secured thereto;

Figure 37 is a plan view of a pre-marked plaster board or the like.

Figures 38 and 39 are respectively sectional and elevational views of amodied form of means for securing the two parts of the double channelmember together.

Figures 40 and 41 illustrate semi-diagrammatically another method andmeans for securing together the two parts of the double channel member;and

Figure 42 is an elevational view, with certain parts broken away, of awall construction illustrating the manner in which the plaster boardsupporting .means act to reinforce the frame members.

Referring now more particularly to the drawings wherein like referencecharacters indicate corresponding parts throughout the several views,and more particularly to Figure 1, it will be noted that there isillustrated a vertical section through a wall and ceiling constructionin Whig!! ih@ mi' erence character 10 indicates the horizontal ceilingframe members and 11 the vertical wall frame members. In Figure l theseframe members are of wood, and as a consequence the manner in which awall constructed in accordance with the present invention is attached towooden frame members will be first described.

As seen from Figure 2, the invention contemplates the attachment ofplaster boards or the like 12 to the frame members 10 or 11 by meansoi.'

means of driven headed elements 14.

The invention contemplates means whereby these channel members may beeconomically produced in large quantities and to this end several formsof channel member and several methods of constructing the same areherein illustrated.

As will be apparent from an examination of Figure 7, one form of channelmember comprises two parts and 16, pre-formed and united in the mannerto be later referred to. The channel member is formed from strips ofsheet metal and the section 16 is bent to the desired cross sectionalcontour in the manner most clearly suggested in Figures 3, 4 and 5.

In Figure 3 it will be noted that the flat strip 16a is bent along thelines 16b to the cross sectional contour illustrated in Figure 4, andthen further bent along the lines 16c wherein the bases 16e of thecompleted channel are provided, together with an intermediate portion16f for attachment to the other section l5 of the channel.

The two sections 15 and 16 of the channel member, illustrated in Figure7, may be united, as for instance, by spot welding, as indicated at 17,or they may be united by cutting tongues from the abutting portions ofthe sections 15 and 16 and bending these tongues back upon the adjacentportion as illustrated in Figures 8 and 9. In Figure 8 there issemi-diagrammatically illustrated a tool 18 having a portion 19 whichmay be run through the channel formed by the bases 16e to the doublechannel member to cut therefrom tongues 20, which are subsequently bentback uponv the abutting portion of the members 15 and 16, as illustratedin Figure 9. This not only secures the members 15 and 16 together toproduce the form of channel illustrated in Figure 7, but Y providesapertures 21 permitting the passage therethrough of the driven headedelements 14, employed for securing the channel members to the framemembers. The formation of the tongues 20 may obviously be accomplishedby a stamping operation.

The outer flanges of the channel members are provided with plaster gaugemeans, which in the present form are shown as pressed out loops orextensions 22. These pressed out loops may be conveniently formed byproducing a pair of spaced parallel short slits and then displacing themetal therebetween outwardly out of the general plane of the flanges inwhich they are formed. The manner in which this might be economicallyaccomplished is illustrated semi-diagrammatically in Figure 6, in whichcooperating forming members 23 and 24 are provided. This operation may911.50 be accomplished by a stamping operation.

les4

By forming the channel illustrated in Figure 7 in two sections ltheplaster gauge projections 22 can conveniently be formed in the section16 before this section is assembled with the section 15,

thus making the production of vthis form of channel member commerciallyacceptable.

In Figures 10 and 11 there is illustrated an improved form of channelmember, formed from a single strip of metal. In constructing this formof channel member the plaster gauge projections 22av wouldin order tofacilitate the manufacture. be formed in the blank 25 before the same isfolded. The blank is folded along the lines 25a, 25h and 25e, to producerespectively the portions 26, 27, 28 and 29 of the completed channelmember illustrated in Figure 11. Itwill be noted that the portions 25and 26 are bent tightly back upon themselves so as to produce a doublewall thickness throughout the greater portion of that side of thechannel member.

rated when the headed element 14 is driven in place, is of but a singlethickness, so that it is unnecessary to perforate these channels as themetal is sufficiently thin, so that the headed element may be driventherethrough and into the frame member 10. This is particularly truebecause the ange 26 of the double channel member is supported directlyagainst the frame member 10 and cannot spring or give when the headedmember 14 is driven therethrough.

It is important to note that in all of the forms of channelsconstituting a part of this invention the head 14a of the drivensecuring element 14 spans the space between the bases of the channelsand engages the side flanges thereof, (see, for instance, Figures 2 and1l) whereby the channel member is rigidly secured in place.

In Figure 12 there is illustrated a modified form of channel member 20;also developed from a single strip of metal, but in this form ofconstruction the side anges 31 are extended beyond the longitudinaledges of the side flanges 32. In this form of construction the plastergauge loops or projections 22h may be formed in the channel member afterthe channel member has been produced, and in Figure 12 there isindicated in dotted lines forming dies or tools 23a and 24a, similar tothe forming dies illustrated in Figure 6.

While heretofore the plaster gauge means has been described andillustrated as consisting of loops pressed out from the general pla-neof the flanges in which they are formed, it will be noted from anexamination of Figures 13, 14 and 15 that various other forms of plastergauge means may be employed. In Figure 13 the double channel member 13has the flanges at one side thereof formed with longitudinally extendingribs 33 which project outwardly beyond the general plane of theseflanges so as to provide a gauge for insuring a minimum thickness ofplaster. In Figure 14 the edges of the flanges of the double channelmember are uted or undulated as indicated at 34, thus producing plastergauge projections or extensions. In Figure 15 the iianges are perforatedas indicated at 35 to produce outwardly extending tubular bosses 36.

It will be understood that when the plaster coat is applied to wall orceiling structures embodying double channel members of any of the formsherein illustrated and described, the plaster enters and lls the channel37 formed by the bases 16e of the opposed channels. It is ofttimesdesirable to provide means acting as an anchorage for the section ofplaster which enters and fills However, the mej dial line of thechannel, which must be perfo this channel 37, and in Figures 16 to 20inclusive, several forms of plaster anchorage means are illustrated. Forinstance, in Figures 16v and. 17 the bases 16e have loops 38 similar tothe' loops 22,

vpressed outwardly therefrom, it being apparent from Figure 17 thatthese loops are staggered with reference to one another, so that theloops of one of the bases 16e project into the spaces between the loopsof the other base 16e. Thus when plasterenters the channel 37 it willextend not only in the spaces under the loops 38, but also in thetortuousspace between this loop to thus provide an adequate anchor forthis section of plaster.

In the modification shown in Figures 18 and 19 the plaste'r anchoragemeans is also employed as a reinforcement for the channel member, and tothis end portions or enlargements 39 are struck out from the bases 16eof the channels, these struck-out portions being arranged in opposedrelation and abutting and they may be welded or otherwise securedtogether if desired, so as to strengthen the bases of the channels ofthe double channel member at this point. Obviously, the plaster swhichenters the channel 37 will flll in around and behind this abuttingprojection 39 so that this section of plaster is also adequatelyanchored. 1

In Figure 20 the anchorage of the plaster coat 40 is accomplished byinclining the bases 16e of the channels to 'provide a tapered orwedgeshaped channel 41, which is smaller at its open side, so that whenthe plaster enters and fills the wedge-shaped channel 41 andsubsequently sets or hardens, the loosening or removing of this sectionof plaster from within the channel will be prevented by reason of thisWedge shape. In

Figures 21 and 22 there is illustrated another Obviously, the channelmembers may be secured to the studding or frame members in other waysthan by driving the headed elements through the medial line or centerthereof, and in Figure 23 the channel member 13 is shown as secured inplace by driven headed elements 44, driven into the studding 1Q at bothsides of the channel member, with the heads 44a thereof overlapping theadjacent edges of the channel member. Obviously these driven elements 44are also passed through the plaster boards l2.

In Figure 24 a construction is shown wherein the driven headed elementwhich is employed for securing the channel member to the studding alsoacts as a plaster gauge, and in this form of construction the drivenelement 45 is shown as provided with an enlarged head 46 which in and ofitself constitutes a plaster gauge.

' In assembling wall or ceiling structures in which the channel membersare secured to the frame members by driven headed elements, a channelmember is first nailed to the frame member, whereupon a plaster board isput in position with one of its longitudinal edges engaged in a channelof the channel member. Thereupon another channel member is engaged withthe opposite edge of the plaster board and this channel member is thensecured to the frame member. This operation is continued until the wallor ceiling is completed. l

In every instance where the longitudinal edges of the plaster boards areengaged and supported by the double channel members, which in turn aresecured to the frame members, the other or adjacent end edges ofadjacent plaster boards may also be reinforced by lengths of doublechannel members which extend between the lengths of channel bars securedto the frame members. In this manner all weaving and relativedisplacement between adjacent edges of adjacent plaster boards isprevented.

While throughout the description thus far the wall and ceiling structurehas been generally described as connected to woodenframe members, itwill be obvious that the present invention also contemplates theattachment to steel frame members. As a consequence, in Figures 25 to 31there is illustrated means for attaching the double channel members tosteel frame members. It will be obvious, however, without specificreference thereto, that any of the heretofore described forms of channelmembers may be utilized notwithstanding the fact that the form ofchannel member illustrated in Figure 7 has been shown in Figure 25.

In Figure 25 the' frame member is in the form of a metal channel'member47 and the channel members 13 are secured thereto by attaching clips 48.AWhile the illustration in Figure 25 is of a ceiling construction, itwill be obvious that the same arrangement and organization of parts maybe employed in connection with walls, in which event the frame members47 would extend vertically instead of horizontally. When metal framemembers 47 are employed in a ceiling construc-` tion they may besupported by suspension elements 47'. As seen in Figure 32, thesesuspension elements can be connected to nails or the like 47" driveninto the wooden frame members 10. In this manner any shrinkage of thewooden frame members 10 which generally causes a distortion thereof attheir lower edges, willnot result in a cracking of the ceilingstructure.

The form of clip illustrated in Figures 25, 26 and 27 consists of achannel portion 49 and a right angularly extending flange 50 with anopen sided slot 5l, thus providing a pair of opposed jaws or lugs 52.Attachment of the clip 48 to the frame member 47 is accomplished inthemanner suggested in Figure 27, wherein one of the jaws 52 is engagedover one of the side flanges of the frame member, the other jaw engagingthe base of the frame member to prevent longitudinal movement of theclip. 'I'he duplicate opposed jaw members or lugs 52 provide means forattaching the clip so that the channel portion 49 thereof may extend ineither direction. l'

In assembling wall or ceiling structures in which the clips 48 areemployed, one of the clips is rst engaged with the frame member,whereupon a channel member is engaged with the clip and then anotherclip is engaged with the other channel of the channel member and withthe frame member. Thereupon the edge of a plaster board is inserted inthe last mentioned clip and the adjacent channel of the channel member,and thereafter another clip is engaged with the opposite edge of theplaster board and with the frame member. Thereafter another doublechannel member, clip and board are assembled with the frame member andwith one another in the manner just described and this sequence ofoperation is continued throughout the assembling of the entire ceilingor wall structure.

In Figure 28 a slightly modiiied form of clip construction isillustrated. In this form of construction the clip .comprises a channelportion 53 and a return bent flange portion 54, slotted as at 55 toprovide the opposed lugs or jaws for engagement with the frame member47.

In Figure 29 the clip comprises a channel portion 56 and a ange portion57 extending laterally therefrom in the same general plane as theadjacent side of the channel portion 56, but slightly offset therefromso that by reason of the slotted portion 58 thereof it may be engagedwith the frame member 47.

In Figure 30 still another form of modlded clip is illustrated, and inthis form of construction the clip is substantially U-shaped, so as tostraddle the frame member 47. Each clip is formed with a pair of channelportions 59 and a vertically extending portion 60, the verticallyextending portion being connected by a horizontal portion or ilange 61so that each clip may straddle the frame member 47 'and rest upon theupper' y flange thereof.

In all of the forms of clips herein illustrated the frame engagingDOrtions thereof may be reinforced or otherwise strengthened by means ofribs 62 pressed therein. A section through the clip shown in Figure 29is illustrated ln Figure 31.

In Figure 33 another modified form of clip is illustrated. 'I'his clipis formed with a channel portion and a 'flanged portion 81 from whichthe jaws. or lugs 82 are struck up preferably by slitting the metal anddisplacing the portion between the slits upwardly to form the opposingattaching lugs or jaws.

In Figure 34 another modified form of clip is shown provided with achannel portion 83 and opposed lugs or jaws 84 formed by slitting theflange 85 thereof from the edge portion inwardly and then bending theslitted portion angularly upwardly and then parallel to the flange 85 toform the opposed attaching lugs.

In Figure 35 still another modified form of construction is shown whichcomprises a channel portion 86 and a ange portion 87 having a returnbent edge portion 88. This forms a portion of double thickness and fromthis portion of double thickness the attaching lugs 89 are struck up.This provides a simple but eillcient means for reinforcing the attachinglugs.

In Figure 36 a modified form of frame member 90 is illustrated, theframe member being bent to form longitudinally extending grooves 91. Inassembling the attaching clip with the frame member 90, the lugs or jawsthereof are adapted to extend into one of the grooves 91 to thus furtherinsure that the clips will not become accidentally disengaged.

In Figure 37 a plaster board 12 is illustrated in plan view, and it willbe noted that the surface thereof is ruled to provide a plurality ofvertical and horizontally extending marks or lines 83. The purpose ofthese lines is to facilitate the cutting of the plaster boards whenboards of smaller dimensions than the standard size boards are desired.By the use of these lines the points at which the board must be cut canbe readily determined by the workman constructing the ceiling or walland the board cut to size rapidly and accurately without necessitatingaccurate measurements and the subsequent marking of the board toindicate the lines of cut.

In Figures 38 and 39 there is illustrated the two parts and 101 of thetype of double' channel member hereinbefore referred to. In this form ofconstruction the infringing parts are united by punching the metal asindicated at 102 to provide a plurality of tongues 103 which aresubsequently tightly bent back upon the adiacent wall structure asillustrated be'st in Figure 38. 'Ihe punching and folding back may becarried out by a rotary or stamping method.

In Figures 40 and 41 still another method and means for uniting the twoparts of the channel member hereinbefore referred to are illustrated. Inthis form of construction the two parts 104 and 105 are united by pairsof tongues which may be conveniently formed by forming members 106 and107, the forming member 106 being shaped to provide a transverse slitand pairs of longitudinally extending slits whereby pairs of tongues 108are provided. Subsequently these tongues can be bent back upon theadjacent metal by means of forming members 109 and 110.

In Figure 42 there is illustrated several of the vertically extendingwooden spaced members 11 illustrated in Figure 1. In practice theplaster boards 111 are secured in place by the double channel members112 which are arranged in longitudinally spaced relation transversely ofthe frame members 1l. These double channel members receive and supportand reinforce the 'adjacent edges of the plaster boards, as previouslypointed out. In practice these double channel members are secured towooden frame members by driven headed elements, such as nails or thelike, andy in Figure 42 two such driven headed elements 113 are shown aspassing through the double chanf nel members at each point ofintersection with a frame member. When the parts are secured in positionthe frame members are rigidly tied together and weaving or relativemovement between adjacent frame members or between the frame 'membersand the plaster board supporting members and the plaster boardsthemselves is prevented. Employment of two driven headed members at eachpoint of intersection of the channel and frame members insures a furtherldegree of' this manner the adjacent edges of the plasterl boards areaccurately aligned and all independent movement or weaving of the boardsat the edges thereof is prevented. Furthermore, the use of an integraldouble channel member facilitates the construction of the wall orceiling and enables the same to be constructed quickly so as to becommercially acceptable and practicable.

In accordance with the present invention the construction of the doublechannel members is such that they may be quickly and economicallymanufactured in large quantities. The association with each form ofchannel member of a vplaster gauge means insures the application of asufcient amount of plaster to the finished wall to insure a commerciallysatisfactory job. Moreover, the numerous other features and details ofconstruction of the various elements comprising parts of this inventionare such as to render this invention of .practical valuein the art.

While several forms of the invention have been described herein somewhatin detail, it will be readily apparent that many other changes andmodifications may be resorted to, without departing from the spirit andscope of the invention,

and to this end reservation is made to make such changes as may comewithin the purview of the accompanying claims.

What I claim as my invention is:

1. In a structure of the class described, a plaster board supportingelement having opposed -channels formed of an elongated at strip ofsufiicient width to constitute one side of each channel and a secondelongated strip shaped to form the bases and other sides of saidchannels.

2. In a ceiling and wall construction, a double channeled plaster boardsupporting element formed of two connected strips of substantially equallength constituting respectively one side of each channel and the othersides and bases of said channels.

3. A double channeled plaster board supporting element for use in walland ceiling structures formed of two strips of sheet metal, one of whichis shaped to form one side and the base of each channel portion, saidelongated strips being united along their longitudinal medial line.

4. A double channeled plaster board supporting element for use inwalland ceiling structures formed of two strips of sheet metal, one ofwhich is shaped to form one side and the base of each channel portion,said strips being permanently connected at their longitudinal centers. v

5. A double channeled plaster board supporting element for use in walland ceiling structures formed of two strips of sheet metal, one of whichis .shaped to form one side and the base of each channel portion, saidstrips being united by tongues struck out therefrom thereby providingapertures, for the purpose set forth.

6. In a structure of the class described, an elongated strip comprisingone side of each of two opposed continuous channels, and a second stripshaped to form the bases and other .sides of said channels.

7. In a Vstructure of the class described, means providing opposedchannels the bases of said channels being spaced from each other, andmeans providing apertures between the spaced bases of said channels forreceiving securing elements by which the channels may be secured as aunit in position.

8. In a structure of the class described, va strip of metal constitutingone side of each of two opposed channels, a second strip of metal shapedto form the bases and lother sides of sauf channels, said second stripofl metal having a web portion which spaces the portions thereofconstituting the bases of said channels, and means providing openingsthrough the web lportion of said v second mentioned strip of metal andthe adjacent( portion of the first mentioned strip to receive securingelements by which the channels may be secured as a unit in position.

9. In a structure of the class described, a strip constituting one sideof each of two opposed channels, a second strip shaped to form the basesand other sides of said channels, said second strip being provided witha web portion spacing the portions thereof constituting the bases ofsaid channels, and tongues struck from the web of said sec-` ond stripand the adjacent portion of said first strip for securing said stripstogether and for providing apertures between the bases of the channels.

GORDON R. WALPER..

